Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2003 Ford F-250 SD owners, lightly cleaned up (personal details are redacted by NHTSA).
Tl* the contact owns a 2003 Ford f250 SD. The contact stated that while driving up an incline approximately 45 MPH, there was a sudden reduction in the engine power and then stalled. The vehicle restarted after numerous attempts. A chemical burning odor emitted outside of the vehicle. The failure occurred sporadically and whenever the fuel tank level registered quarter of a tank. The vehicle was taken to an independent mechanic who stated the fuel tank lining was severely damaged and the fuel tank needed to be replaced. The vehicle had not been repaired. The manufacturer was not notified of the problem. The approximate failure mileage was 140,000.
Tl* the contact owns a 2003 Ford f-250 SD. While the vehicle was parked, the contact noticed that the fuel tank was hanging down. The contact looked underneath the vehicle and saw that the fuel tank strap was fractured and the fuel gauge was damaged. The dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was made aware of the failure and stated that the VIN was not included in a recall. The failure mileage was 49,000.
I own a 2003 Ford f250 7.3l diesel. Since jan. 2004 the vehicle began "hiccuping" or "missing" just for a split second while driving. I took the vehicle in for service in feb. & the dealer said there were "no codes, no failures". Truck continues to miss & then the condition worsened by stalling while driving & I have no power steering. I am able to restart the vehicle & go about my way, all the while worrying when & where I will be when it happens again. I have started to log all of the "misses" & "stalls" since the 2nd visit to the Ford dealership when they told me the "computer says nothing is wrong & unless it happens to the dealership when they test drive it, there is nothing they can do for me." my brother-in-law has a friend that owns the same truck & apparently has had the same problem, but he eventually ended-up breaking down. …
I have had rough idle problems since I bought the truck new. This was the first diesel vehicle I have ever owned so in the beginning I thought it was normal, but it kept getting worse. I purchased the truck in April 2003. I have had hard shifting since I bought it. When I back the truck up and then shift into drive it will slam into gear as a vehicle with no transmission fluid reacts. There was a dangerous hesitation when crossing traffic and sometimes the truck would have a 3-5 second stall. It has blown white smoke more recently and would not kick down into passing gear on the freeway. I have had the truck in for service several times and the last time they told me that they had no fix at that time. I just got off the phone with a customer service manager and she tells me that the fix will raise the noise level up 5 decibels. …
I purchased a 2003 Ford f-250 super duty crew cab with 6.0 diesel in late January of this year. The check engine light came on in oregon. I pulled into the Ford house in coos bay on Saturday. They couldn't work on it until Monday. Tuesday they said it was an injector seal problem. They said they drained 28 quarts of fluid from the crankcase, which had a 15 qt capacity. The rest, they said, was diesel blow-by. They replaced 3 sensors and 1 injector and installed a new computer update. We picked up the truck and left town the following Thursday. On the way out of town the turbo intake hose blew off. We returned and had it fixed. Several days later we were in texas when the turbo exhaust hose blew off. That, too was repaired. At home, the truck was running rough and the fuel mileage dropped from 20 mpg to 13 mpg. …
We were returning home from a trip to charlotte, nc yesterday afternoon when we were stopped by another motorist at the intersection of south college road and carolina beach road in wilmington. The driver had been following us for approximately one mile and his truck was covered with diesel fuel from our new Ford f250. Apparently the fuel system had started leaking. He looked under the truck and advised us to pull off as soon as the traffic signal allowed us to move. There was a puddle of diesel fuel under the truck sufficient to cause the rear tires to slip. We pulled into the parking lot and noted the rear and underside of the truck were coated with diesel fuel. Fuel continued to leak until we shut off the engine. Apparently the fuel system was damaged or defective. We have had the truck towed to cape fear Ford in wilmington, north carolina.
I have a 2003 Ford f250 w 7.3 diesel. Last year it broke down,just quit, finally started, need a new in tank pump, was told by Ford dealer it had ?!@#$% in the tank, spent $1000. 2 weeks ago it start messing up again. Ford said it needed a new computer,3 days after repaired it started bucking again.Ford could not find anything. After making several inquires, I find Ford has a serious problem with the coating coming off inside the fuel tank and wreaking pumps, filters injectors etc. Also they are refusing to do anything. Since this can be very dangerous, quitting at any time, I hope NHTSA will make Ford fix this problem or advise where to join a class action suit, since im tired og spending money and not able to finally fix this problem and depend on my truck.
Extremely poor fuel economy on Ford 7.3 l diesel engine. Bought vehicle new approx 1 year ago, vehicle was getting 18 miles per gallon until dec. 2003. As of jan. 2004 the vehicle mileage has been 9 miles be gallon. Vehicle has loss of power and has been in the dealer repair shop for this problem. Ford diagnostic say there is not a problem with the engine. If anything, a diesel engine should get better mileage as it is broken in. Current vehicle mileage is approx. 25500 miles. This vehicle has been regularly serviced, oil change, filter, air filter, fuel filter every 3000 to 4000 miles and has been to the same dealership for the same complaint two times before without correction.
Tl contact owns a 2003 Ford f250 super duty. While driving 65 MPH, the vehicle suddenly stalled and shut off. The vehicle was unable to be restarted and was towed to the contact's residence. A few days later, the vehicle still failed to start after a few attempts. The vehicle was towed to the dealer and they stated that a new fuel injection control module was needed. The manufacturer stated that the VIN was not included in NHTSA campaign id number 05V270000 (electrical system). The vehicle is currently being repaired at the contact's expense, but he believes that it should have been included in the recall. The current and failure mileages were 58,000.
Tl* the contact owns a 2003 Ford f-250 SD. The contact stated that while performing an oil change, he noticed that the frame was rusted severely.the contact performed a thorough inspection of the vehicle and also discovered that the fuel tank straps were severely rusted. The front strap was completely detached from the vehicle and the second strap was partially hanging from the vehicle. The manufacturer was contacted and advised him that the vehicle was not included in NHTSA campaign id number 11V385000 (fuel system, gasoline:storage:tank assembly:mounting). The vehicle was not repaired. The failure and current mileages were approximately 125,000.
Fuel System complaints in other F-250 SD years
Frequently asked questions
How common are fuel system problems on the 2003 Ford F-250 SD?
NHTSA has 24 complaints about the fuel & propulsion system of the 2003 Ford F-250 SD, 13% of the model year's 178 complaints. The component named most often is fuel injection system (3 mentions).
Is there a recall for 2003 Ford F-250 SD fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2003 Ford F-250 SD, though it has 4 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2003 Ford F-250 SD fuel system problems start?
Half of the complaints with a recorded mileage happened before about 49,000 miles, and 50% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 1 fire and 0 injuries to fuel & propulsion system problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.